Version 4.0 01/04/05 v1

D-3400ce-UW Installation & Startup

Controller System

Mechanical Installation

IL321-D-ALL

120 mm( 4.72")

(M5)10 - 24

1. Drill 2 holes in the mounting surface 120 mm (4.72”) apart.

IL322-ALL 2. Secure the large bracket to the mounting surface with appropriate pan head or flat head fasteners.

50

20

100%0

MANUEL/ AUTO

TENSION OFF/ON

MANUEL

OUTPUT

Type: D-3000-ce-UWSN: 6105 U : 230/115VI : <0.5A F : 50/60Hz

IL162 Mount the controller in a dry place, away from any source of heat. Mount the controller in an area free of excessive vibration. If possible, mount the controller at eye level and in a location that is accessible to the operator. If an I/P converter is used, mount it as close to the brake as possible.

IL323-ALL 3. Place the small bracket in the bottom slot on the back of the controller. Place the controller on the large bracket on the mounting surface. Slide the small bracket to the center of the controller and mark the mounting surface through the hole in the bracket.

IL324-ALL 4. Slide the small bracket to one side. Drill a mounting hole for the small bracket as marked in step 3. Slide the small bracket back into place and secure with an appropriate pan head or flat head fastener.

D-3400ce-UW

2 Version 4.0 01/04/05 v1

Pneumatic Installation Connect main air supply (1) to the air filter (2), the air filter to the I/P-converter (3), and the I/P converter to the brake cylinders (4) (see diagram). Recommended: Install an air pressure gauge / manometer in line with the brake if the gauge is not present on the I/P converter.

1

23

5u

4

PR304-XD340-UW-ALL

Electrical Installation

Failure to follow installation and setup instructions in this manual may result in equipment damage or personal injury. Failure to follow wiring instructions in this manual may result in equipment damage, personal injury, or death. WARNING: Electrical installation must be done by skilled personnel. Wiring must meet all applicable codes and standards.

I/P Converter

Connect the cable from the controller to the I/P converter (see diagram).

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

PE

230

115

L N

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

22 2

3 24

25

26

27 2

8 2

9

12345

6789

Type : xxx3400PcexxVoltage : 11 5 / 230 V ACCurren t : <200 mAS. nr . : 3 000

Run Mode AUTO

WD384-ALL340-US

I/P Converter

15

16 1

7

0V 4 - 20 mA

0 - 10VCable from Controller to I/P Converter

RegulatedOutput:

0V4 - 20 mA

24V(-) GND

PS

(+) Signal

*Connect if I/P converteruses a 24V power supply.

0V

24V

1 2

3

4

Shield /Ground

*

D-3400ce-UW

3 Version 4.0 01/04/05 v1

Connection of the Start/Stop (Run) Signal from the Machine Main Panel

Connect the cable between the machine main panel and the controller. The signal must come from a relay with the following function: The relay must: • energize when the machine starts

running or moving • de-energize when stop is pressed or

when the machine comes to a complete stop (zero speed signal).

From this relay, use the closing function (NO). The relay contact must be closed during operation of the machine and open at stop (see diagram).

START

STOP

K100

K100

24V

DI-5Run /

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9K100

11 (COM)

13 (NO)Run Relayto Main Motor

Controller

WD373-340-W-US

Dancer Potentiometer

Connect the cable from the controller to the dancer potentiometer (see diagram).

30 3

1 32

33

34 3

5 36

37

38

39

40 41

42

43 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

PE

230

115

L N

1 2

3

4

5

6 7

8

9

10

11 1

2 13

14

15

16 1

7 1

8 19

20

21 2

2 23

24

25 2

6 27

28

29

12345

6789

Type : xxx3400P cexxVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

Run Mode AUTO

Cable from Controller to Dancer Potentiometer

11 1

2 13

14

2.5V

-2.5V

+Input

0V

10 K

10 K

Ground / Shield

WD385-D340-US

D-3400ce-UW

4 Version 4.0 01/04/05 v1

WARNING: Electrical installation must be done by skilled personnel. Wiring must meet all applicable codes and standards.

Connection of Supply Voltage to the Controller

1. Turn off the power in the machine main panel.

2. Choose the supply voltage (230/115V AC) that is applied when the power to the machine main panel is turned on. Set up the voltage switch on the controller accordingly. Note: We recommend to use the main supply before the emergency stop circuit so that the controller stays under power during emergency stop.

3. Run a cable from the machine main panel to the controller.

4. Remove the fuse from the fuse holder on the controller if a fuse is already installed.

5. Connect the cable to the controller (see diagram) and connect the cable to the machine main panel (see item 2).

6. Turn on the machine main panel again.

7. Check the connection and voltage of the terminal points L, N and PE, using a voltmeter.

30 3

1 3

2 3

3 3

4 3

5 3

6 37

38

39

40 4

1 42

43

44

45

46 4

7 4

8 49

50

51 5

2 5

3 54

55

56 5

7 58

PE

230

115

L N

1

2

3

4

5 6

7

8

9

10

11

12 1

3 1

4 15

16

17

18

19 2

0 2

1 22

23

24

25

26

27

28 2

9

12345

6789

Type : xxx3400PcexxVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

Run Mode AUTO

L N PE

220

230

115

Max.10mm

Voltage Switch ( In 230V Position )

Fuse Holder

FUSE SIZE:115V -160mA T (slow blowing type) Dim. 5 x 20 mm230V - 80 mA T (slow blowing type) Dim. 5 x 20 mm

PE L N

WD377-ALL340-US

8. Turn off the power to the machine main panel.

9. Insert the correct fuse and turn on the power to the machine main panel.

D-3400ce-UW

5 Version 4.0 01/04/05 v1

Using the Keypad The controller operates in two modes, scroll and edit (the cursor blinks) and has four types of menu items: parent menu, submenu, numeric parameter, and textual parameter. Scroll moves through the menu items; edit changes the numeric or textual value of the parameters.

Scroll mode: moves to the previous menu or parameter.

Edit mode: increases the numeric parameter value or moves to the previous textual parameter value.

Scroll mode: moves to the next menu or parameter.

Edit mode: decreases the numeric parameter value or moves to the next textual parameter value.

Scroll mode: jumps one level back to the previous menu.

Edit mode: cancels edit mode, returning to the previous numeric or textual parameter value.

Scroll mode: enters the previous menu or changes to edit mode, if a numeric or textual parameter.

Edit mode: Press once (the cursor blinks) to enter a numeric or textual parameter. After change, press once again to store the change.

Complete Menu Tree Run Mode Status Menu Version Dancer Setpoint Output I-Level Gain Level Manual Diameter Aux1 In Aux2 In Aux3 In Aux1 Out Aux2 Out Password Setup Menu *) Config Menu Ctrl Type Amplifier Restore Confg Options Menu Use Stop Use Taper Use Dig Out Use Splice Use Rng Exp Use Aux1 In Use Aux2 In Use Aux1 Out

DI Mode Menu DI-5 Invert DI-8 Invert Regulator Menu Gain Menu Gain Min Gain Max Source Gain Level PID Menu P Level I Time D Level Roll Change Menu New Output New Roll D Start Menu Start Lev Stop Menu Hold Menu Hold Delay Hold Level Diameter Menu Dia Source P/Rev Roll mm/Pulse Dia Min Dia Max Diameter Taper Menu Digital Out Menu Splice Menu Range Exp Menu

Aux1 Input Menu Aux1 Calc Aux1 Raw Raw1 Min Raw1 Max Calc1 Min Calc1 Max Calc1 Invert Aux2 Input Menu Aux1 Output Menu Com Menu Com Type BaudRate Remote Menu Enable Menu Value Menu

*) Access with password 5. Note: The above menu tree is a standard configuration to be used in connection with the installation and startup of the D-3400ce-UW controller. Menus in black, bold text are visible and active menus. Menus in grey are optional functions that can be selected under the options selection menu [Options Menu] . If selected, the menus for the chosen functions become visible in the display. For a brief description of the options selection menu, see the last page of the installation and startup instructions for the D-3400ce-UW controller.

D-3400ce-UW

6 Version 4.0 01/04/05 v1

Connection of the Diameter Signal The controller default is set up to use a diameter signal coming from two proximity switches. Optional is a diameter signal coming from an ultrasonic sensor. Below you will find a description of both connection solutions. Note: Only one of the connection solutions is to be used at a time.

Proximity Switches

Connect the proximity switches (see diagram).

Go to the parameter [Password] - enter 5. Enter the [Setup Menu] and step down to the [Diameter Menu]. Set up the following parameters: [P/Rev Roll] (Roll Pulse): Number of pulses per revolution on the roll (Roll Pulse). (Recommended: 4 pulses.) [mm/Pulse] (Web Pulse): mm between pulses on the main machine (Web Pulse). (Recommended: 10-20mm.) [Dia Min]: Minimum roll size in mm. [Dia Max]: Maximum roll size in mm.

DancerWD342-DDTI340-UW-US

24V

+24 S0V

Web Pulse Roll Pulse

+24 S0V

PNP PNP

0V

1 2 3 4 5 6 7 8 9 10

30 31 32 33 34 35 36 37 38 39

Brake

Ultrasonic Sensor

Connect the ultrasonic sensor (see diagram).

Go to the parameter [Password] - enter 5.

Enter the [Setup Menu] and step down to the [Diameter Menu]. Set up the following parameter: [Dia Source]: Change the diameter source from [PULSE] to [AUX1]. The controller will now use the 0 – 10V on terminal 51 as diameter. 0V = Center of core 10V = Maximum diameter

DancerWD343-DDTI340-UW-US

0V

10V

24V

24S 0V

Ultrasonic

0V

36 37 50 51 52

D-3400ce-UW

7 Version 4.0 01/04/05 v1

Dancer Calibration

1. Check for correct installation of the dancer potentiometer.

2. Place the dancer in center position, loosen the potentiometer coupling, and turn the potentiometer shaft until it is approximately in center position (5K between the two wires – see below). Tighten the coupling.

10 K

Ohm-meter

3. Apply power to the controller and let it warm up for at least 10 minutes. Scroll to the [Dancer] parameter in the [Status Menu].

5. Place the dancer in maximum position. If a negative value is displayed, switch the two wires in terminal 12 and 14 coming from the potentiometer, and repeat step 4. Adjust potentiometer R2 until [Dancer 100%] appears. If the value is below 100%, turn R2 clockwise; if above, turn counter clockwise.

Cen ter (0% )

M in. (-100% )

M ax. (1 00% )

Dancer

IL018

R1 R2 R3 R4 R5 R6

DO 4DO 3DO 2DO 1

00

IL345-D340ALL

Status Menu Version Dancer Setpoint Output I-Level Gain Level Manual Diameter Aux1 In Aux2 In Aux3 In Aux1 Out Aux2 Out

4. Place the dancer in center position and adjust potentiometer R1 until the digital display shows [Dancer 0%] under the [Status Menu]. Note: R1 and R2 are 25-turn potentiometers, so many rotations may be required.

DancerC e n te r (0 % )

M in . (-1 0 0 % )

M a x . (1 0 0 % )

IL017

R1 R2 R3 R4 R5 R6

DO 4DO 3DO 2DO 1

00

IL344-D340ALL

6. Move the dancer to minimum position. The display should show -100%. • If the value is under -100%, move center

position towards minimum position. • If the value is over -100%, move center

position towards maximum position. To readjust center position, return to step 4.

D-3400ce-UW

8 Version 4.0 01/04/05 v1

Startup and Adjustment

1. Scroll to the [Password] menu. Press ENTER, then UP key to change display to 5 and press ENTER again. Password 5 allows access to the [Setup Menu].

7. Run the machine at low speed and adjust [Gain Max] until the dancer is steady but still responsive to variations.

2. Scroll to the parameter [Gain Min] under the [Regulator Menu].

3. Place a small roll in the unwind stand.

4. Run the machine at low speed and adjust [Gain Min] until the dancer is steady but still responsive to variations.

5. Stop the machine and scroll to the parameter [Gain Max] under the [Regulator Menu].

Status Menu Password Setup Menu Config Menu Ctrl Type Amplifier Restore Confg Options Menu . Regulator Menu Gain Menu Gain Min Gain Max Source Gain Level PID Menu P Level I Time D Level Start Menu Start Lev Hold Menu Hold Delay

6. Place a large roll in the unwind stand.

8. Scroll to the [Hold Menu] and adjust the hold delay time [Hold Delay] so that it fits the deceleration ramp of the machine. • If the signal for start (terminal 34) goes low

before the machine reaches zero speed, enter the time between maximum and zero speed in the parameter [Hold Delay].

• If the signal for start (terminal 34) goes low only when the machine reaches zero speed, set the time in the parameter

[Hold Delay] to 0.2 seconds.

OPERATOR'S GUIDE

Need more info? Visit us at www.montalvo.com or service@montalvo.com © 2005 Montalvo

0

2040 60

80

%100

0

20

40 60

80

100

w w w . m o n t a l v o . c o m

MANUAL/AUTO

TENSIONON/OFF

LOW/HIGH

TENSIONON/OFF

X-3400ce-UW (unwinder with load cells)

OPTIONS

Green Power LED - Indicates that power is on.

Tension Meter - Displays actual web tension. The scale can be either in Newton, kg, lb or %.

Output Meter - Displays the regulated output of the controller in %. This output represents the pressure on the brake of the roll.

Manual / Auto - Switches between manual and auto mode.Manual: The operator controls the brake pressure directly by using the manual potentiometer.Auto: Automatic regulation of the brake pressure to maintain a constant web tension. When switching from manual to auto mode, the controller continues to regulate from the manual level.Note: The brake pressure automatically decreases along with the decrease of the roll diameter.

Tension On / Off - Turns tension on and off. Output is zero when off. Typically used for roll change or release of roll. After turning tension on, run the machine slowly for the first 10 seconds to ensure that the controller has calculated new data.

Auto Setpoint - In auto mode, sets the controller to run with a desired web tension. By increasing the setting, the web tension will be increased. The settings 0 to 100% represent 0 to full scale of the tension meter.

Manual Setpoint - In manual mode, controls directly the brake pressure. The setting 0 to 100% represents 0 to maximum brake pressure.Note: Observe the tension on the tension meter, and adjust the manual setpoint accordingly. To maintain a constant tension – the operator has to decrease the brake pressure along with the decrease of the roll diameter by using the manual potentiometer.

OPTIONS

Low / High Scale - Switches between low and high scale. The setpoint settings represent the tension setting based on the selected tension scale (low/high).Note: When switching between low/high scales during operation, the controller will automatically regulate to the setpoint setting (in %) based on the new tension scale. We recommend changing the setpoint setting to the same % value of the new scale synchronously with the scale switching.

Splice Setpoint - Used in automatic roll change applications (flying splice). The setting applies for the new incoming roll diameter. The new diameter is transferred to the controller exactly when the knife is cutting the web.Note: Before performing the flying splice, it is important to set the splice potentiometer approx. at the setting that represents the new incoming roll diameter (0-100%).

0

2040 60

80

%100

0

20

40 60

80

100

w w w . m o n t a l v o . c o m

MANUAL

0

50

80

100%

20

AUTO

0

50

80

100%

20

SPLICE

0

50

80

100%

20

MANUAL/AUTO

LOW/HIGH

MANUAL

0

50

80

100%

20

AUTO

0

50

80

100%

20

SPLICE

0

50

80

100%

20

OUTPUT

OUTPUT

D-3400ce-UW

10 Version 4.0 01/04/05 v1

Basic Diagram - Cabinet Version

50

20

100%0

MANUEL/ AUTO

TENSION OFF/ON

MANUEL

OUTPUT

Type: D-3000-ce-UWSN: 6105 U : 230/115VI : <0.5A F : 50/60Hz

IL162

DancerPotentiometer

10 K

1412 13

WD326-D340-UW-US

Voltage0 - 10V

- +

REGULATED OUTPUT

15 16 17

4 - 20mACurrent

4

* * S e e

b e l o wn o t e

* * C o n n e c t w i r e i f c o n v e r t e r u s e s2 4 V p o w e r s u p p ly

L N

Power Supply115 / 230V AC

PE is connected to 0VPE

10 K

Proximity Switches

24 S 0V

Web Pulse Brake Pulse

24 S 0V

PNP PNP

24V

0V

34 36 6

Run FastStop

33 5 1 35 5150

0-10VAux1 Input

Diameter

Analog Input0-10V

or

0V

Multi C

able

Multi Connector

10 K

Manual

10V

GN

D TensionOff

GN

D

10V

24VOutput

100 K

Front Panel

4 517 12 13128 Multi Connector

Manual

D-3400ce-UW

11 Version 4.0 2005/01/01 v1

Customer Parameter Settings Note: Menus in black, bold text are visible and active menus. Menus in grey are optional functions that can be selected under the options menu . If selected, the menus for the chosen functions become visible in the display.

Parameter Name Value Min. Max. Unit Config Menu Ctrl Type - - -

Amplifier X1 X10 -

Restore Confg NO YES -

Options Menu Use Stop NO YES -

Use Taper NO YES -

Use Dig Out NO YES -

Use Splice NO YES -

Use Rng Exp NO YES -

Use Aux1 In NO YES -

Use Aux2 In NO YES -

Use Aux1 Out NO YES -

DI Mode Menu DI-5 Invert NO YES -

DI-8 Invert NO YES -

Regulator Menu Gain Menu Gain Min 0 50 %

Gain Max 0 500 %

Source - - -

Gain Level 0.0 100.0 %

PID Menu P Level 0 255 -

I Time 10 255 -

D Level 0 255 -

Roll Change Menu New Output 0.0 500.0 %

New Roll D 0.0 100.0 %

Start Menu Start Lev 0 200 %

Stop Menu Source - - -

F-Stop Min 0.0 20.0 %

F-Stop Max 0.0 500.0 %

Hold Menu Hold Delay 0 99.9 S

Hold Level 0 200 %

Diameter Menu Dia Source - - -

*P/Rev Roll 0 8 -

*mm/Pulse 0 400 mm

Dia Min 5 3000 mm,%

Dia Max 5 3000 mm,%

**Dia Factor 0.0 900.0 %

**DF AutoSet 0.0 100.0 %

Diameter 0.0 100.0 %

Taper Menu Type LIN EXP -

Tap Begin 5.0 50.0 %

Digital Out Menu DO Select Menu Web Break - - -

Diameter - - -

Lo Tension - - -

Hi Tension - - -

Wbr Delay 0.1 20.0 S

Wbr Level -95.0 25.0 %

Wbr Time 0.0 5.0 S

Alarm Dia 0.0 100.0 %

Lo Level 0.0 100.0 %

Lo Delay 0.0 5.0 S

Hi Level 0.0 100.0 %

Hi Delay 0.0 5.0 S *Visible if and only if diameter source = PULSE. **Visible if and only if diameter source = OUTPUT.

D-3400ce-UW

12 Version 4.0 2005/01/01 v1

Customer Parameter Settings

Parameter Name Value Min. Max. Unit Splice Menu Spl Source - - -

Spl Delay 0.0 3.0 S

Spl Level 0.0 200.0 %

Spl Time 0.0 9.9 S

Range Exp Menu RE Source - - -

Ranges 1 4 -

Start No. 1 4 -

Dn Level 0 100 %

Up Level 0 100 %

Range Time 0 60 S

Brake Menu Pads R1 0 20 -

Pads R2 0 20 -

Pads R3 0 20 -

Pads R4 0 20 -

Randomize NO YES -

Range Dia Menu 4->3 Dia 0.0 100.0 %

3->2 Dia 0.0 100.0 %

2->1 Dia 0.0 100.0 %

Aux1 Input Menu Aux1 Calc 0.0 100.0 %

Aux1 Raw 0.0 100.0 %

Raw1 Min 0.0 100.0 %

Raw1 Max 0.0 100.0 %

Calc1 Min 0.0 100.0 %

Calc1 Max 0.0 100.0 %

Calc1 Invert NO YES -

Aux2 Input Menu Aux2 Calc 0.0 100.0 %

Aux2 Raw 0.0 100.0 %

Raw2 Min 0.0 100.0 %

Raw2 Max 0.0 100.0 %

Calc2 Min 0.0 100.0 %

Calc2 Max 0.0 100.0 %

Calc2 Invert NO YES -

Aux1 0utput Menu Source - - -

Output 0.0 100.0 %

Aux1 Min 0.0 100.0 %

Aux1 Max 0.0 100.0 %

Aux1 Offst 0.0 25.0 %

Com Menu Com Type - - -

BaudRate 4800 38400 -

Remote Menu Enable Menu

Value Menu

D-3400ce-UW

13 Version 4.0 2005/01/01 v1

Options Selection Menu [Options Menu] This menu offers a number of optional functions, to be enabled or disabled (choose NO or YES), and as such is building a supplement to the basic functions of the controller. If a controller is ordered including one or more options, they will be set up from the factory. Note: If enabled, an optional function will appear in the menu tree, and if disabled, it will disappear from the menu tree. Set up the parameter as follows: [NO] = option is disabled [YES] = option is enabled

Name Function Description

Use Stop The stop option is used to prevent a drop in the dancer when the machine is stopping. Typically it is necessary if the machine has a fast stop function or if the machine is stopping with a short ramp-down time.

Use Taper The taper options are only used in a single zone machine. Use Dig Out The [Digital Out Menu] offers the options web break or diameter

alarm. Use Splice The splice option is used to control a splice sequence (automatic roll

change). Use Rng Exp The range expander option is used to divide the torque capabilities of a

braking system into multiple ranges. The advantage of this function is that the required torque is controlled automatically.

Use Aux1 In When this parameter is enabled, the analog Aux1 input is available to use.

Use Aux2 In When this parameter is enabled, the analog Aux2 input is available to use.

Use Aux1 Out When this parameter is enabled, the analog Aux1 output is available to use.

Setup Menu Config Menu . . . Options Menu Use Stop Use Taper Use Dig Out Use Splice Use Rng Exp Use Aux1 In Use Aux2 In Use Aux1 Out DI Mode Menu Regulator Menu . .

DI Mode Menu Offers the possibility of inverting the functions of different input signals, e.g. DI-5 Run signal and DI-8 Fast Stop signal.

The Montalvo Corporation Danarota Technic A/S 50 Hutcherson Drive . Gorham, Maine 04038 USA Gl. Skartved 5, DK-6091 Bjert Tel: 800-226-8710 or 207-856-2501 Tel: +45 75 57 27 11 Fax: 800-644-5097 or 207-856-2509 Tel: +45 76 31 13 57 (service & support) Email: info@montalvo.com Fax: +45 75 57 29 97 Website: www.montalvo.com Email: info@danarota.dk Email: service@danarota.dk Website: www.danarota.dk